A novel tool path planning method for 5-axis single-point diamond turning

Abstract

5-Axis single-point diamond turning adds two linked axes based on 3-axis single-point diamond turning, which can smoothly and continuously process complex surfaces. Compared to 3-axis turning, tool path planning for 5-axis single-point diamond turning is a complex decision-making process, which is a novel problem in the existing studies and a difficulty in multi-axis turning. In this study, a novel path planning method for 5-axis single-point diamond turning is proposed. Firstly, the mapping relation from scallop height to the distribution of cutter contact (CC) points is established in the non-uniform rational B-spline (NURBS) parameter space, thereby the planning of CC points is quickly achieved under fewer constraints. Furthermore, the local interference and global interference generation mechanism of 5-axis single-point diamond turning are revealed by geometrical analysis, combining diamond tool parameters and tool shank parameters. By transforming the motion of the cutter axis posture in 3D space into swings in two planes, the posture accessibility diagram of the cutter axis is efficiently constructed. Finally, the feasibility and effectiveness of the tool path planning method are verified by 5-axis single-point diamond turning experiment. And the contour accuracy is improved through the quadratic planning of the CC points (the contour accuracy after compensation is 3.2 μm compared to normal one 9.6 μm). This study extends the traditional 3-axis turning to 5-axis turning, providing a new perspective for the machining of complex surfaces.